Sorting materials using pattern recognition, such as upgrading nickel laterite ores through electromagnetic sensor-based methods

ABSTRACT

A system and method of sorting mineral streams, for example laterite mineral ores, into appropriately classified valuable and waste streams for maximum recovery of value from the mineral stream, e.g., a stream of minerals includes receiving response data indicating reflected, absorbed or backscattered energy from a mineral sample exposed to a sensor, where the mineral sample is irradiated with electromagnetic energy. The system determines spectral characteristics of the mineral sample by performing spectral analysis on the response data of the mineral sample and identifies a composition of the mineral sample by comparing the spectral characteristics of the mineral sample to previously developed spectral characteristics of samples of known composition. The system then generates a sort decision for the mineral sample based on the comparison, where the sort decision is used in diverting the mineral sample to a desired destination e.g. pyrometallurgical treatment stages, or to a waste stream.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 13/830,453, filed on Mar. 14, 2013, entitled “Sorting Materials Using Pattern Recognition, Such as Upgrading Nickel Laterite Ores Through Electromagnetic Sensor-Based Methods,” which claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 61/640,749, filed on May 1, 2012, entitled “A Method For Upgrading Nickel Laterite Ores Through Electromagnetic Sensor-Based Methods,” and is a continuation-in-part of U.S. application Ser. No. 13/538,931, filed Jun. 29, 2012, entitled “Extracting Mined Ore, Minerals or Other Materials Using Sensor-Based Sorting,” which in turn claims the benefit of U.S. Provisional Application No. 61/502,772, filed on Jun. 29, 2011, entitled “Method for the Pre-Concentration of Mineral Ores” and U.S. Provisional Application No. 61/502,760, filed on Jun. 29, 2011, entitled “High Frequency Electromagnetic Spectrometer,” all of which are hereby incorporated by reference for all purposes in their entireties.

BACKGROUND

Material extracted from the earth may be processed using various mining processes. Using various techniques, after materials are mined from the ground, they are typically blended to achieve as much as possible a homogeneous condition. Thereafter, those portions of the blended material that have no beneficial use or value are typically separated or extracted from the portions of the material that have beneficial use or value by various conventional means.

For example, rock material may be mined using explosives, excavated and then transported to crushers that crush the rock material into smaller grain size. After crushing, the rock material may be further ground finer in grinding mills. The process may also include a vibrating screen that classifies the crushed or ground material into desired grain sizes. Next, valuable minerals may be concentrated by removing unnecessary substances from the excavated rock material. The separation process may include leaching, flotation, gravity methods and magnetic separation, or concentration by pyrometallurgical methods.

After separating the most valuable fragments, metal may be extracted from the mineral. Common extraction methods include pyrometallurgy (a metal production method employing high temperatures), alternately hydrometallurgy (producing metal by leaching the raw material and precipitating the pure metal from the solution) and alternately electrometallurgy (a metal production method applying electricity).

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the present disclosure will be described and explained through the use of the accompanying drawings in which:

FIG. 1 illustrates an example of an arrangement for a sorting machine;

FIG. 2 illustrates an example of a control system with embedded pattern recognition and discrimination algorithms;

FIG. 3 illustrates an example of an arrangement of a sorting system;

FIG. 4 is a flow chart having an example set of instructions for identifying mineral composition; and

FIG. 5 an example of a computer system with which one or more embodiments of the present disclosure may be utilized.

The drawings have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be expanded or reduced to help improve the understanding of the embodiments of the present invention. Similarly, some components and/or operations may be separated into different blocks or combined into a single block for the purposes of discussion of some of the embodiments of the present invention. Moreover, while the disclosure is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the disclosure to the particular embodiments described. On the contrary, the disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

DETAILED DESCRIPTION

In the field of mineral extraction and beneficiation, several methods exist for the extraction and beneficiation of lateritic nickel ores to ferronickel. Lateritic deposits are so named in cases where silica has been selectively leached from a nickel containing ultramafic magnesium-aluminosilicate deposit, selectively concentrating the nickel in heterogeneous proto-horizontal layers. Mining by mechanised open pit methods is common, however two principal beneficiation methods are used depending on the specific composition of the ore.

Iron-rich, predominantly limonitic ores are mined, blended, and treated hydrometallurgically, either by acid heap leach at atmospheric pressure, or by pressurized acid leach methods. Ferronickel is produced from the leachate by precipitation and electrorefining. Silica-rich predominantly saprolitic ores are treated pyrometallurgically firstly by calcining the crushed, mined and blended saprolite, and then smelting of the calcine, by either AC or DC methods. Lateritic deposits are seldom solely of one type or the other and generally contain significant quantities of both limonite and saprolite as well as intermediate or transition material, plus remnant silica basement material along with other diluents presented in a highly heterogeneous manner.

Each method is therefore compromised in the presence of too much of the other lithology (i.e., too much saprolite in the limonite when hydrometallurgical routes are selected, and too much limonite in the saprolite when pyrometallurgical methods are selected). Both treatment methods are compromised in the case of unilaterally low grades of nickel.

A novel solution to the common challenge of economic processing of laterites is described herein. It is possible to determine the variable chemical composition of unblended mineral samples or streams by exposing the mineral sample or stream to electromagnetic radiation and measuring a signal produced therefrom, such as an absorption, reflectance or Compton backscatter response. A machine comprising arrays of source-detector-type mineral sensors, coupled to high-speed, digital signal processing software incorporating rapid pattern recognition algorithms scans the ore stream in real-time and interprets the chemical composition of the ore. An array of physical diverters connected to the sensor array via a high-speed, real-time machine control layer are actuated to deflect the mineral sample or stream when the mineral composition as measured by the sensor array reaches a certain pre-determined value.

Embodiments of the present invention applied in the form of arrays of the described machines, sensibly arranged in a logical process sequence, can process large quantities of unblended laterite material mined unselectively at high throughput rates into streams of material simultaneously curated either for hydrometallurgical-optimal treatment, pyrometallurgical-optimal treatment, or as a waste product for disposal back into the mining void. Accordingly, in some embodiments, multiple economic streams from one deposit may simultaneously be produced using sensor-based methods.

Embodiments of the present invention described herein depart from conventional practice whereby in some described embodiments, the recovered value of mineral ores is maximized by preserving the natural heterogeneity of the mineral ore as much as possible by not blending the mineral ore prior to introducing it into a sorting system trained to recognise distinct species within the heterogeneous material. In some embodiments, a sorting system may then simultaneously classify the mineral ore into several fractions of arbitrary but variant value for processing in separate treatment streams (including a waste stream designated for disposal), thereby maximizing the recovered value of the mineral ore.

While multiple embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. As will be realized, embodiments of the present invention are capable of modifications in various aspects, all without departing from the scope of the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

The terminology used below is to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific examples of the invention. Indeed, certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section.

FIG. 1 illustrates an example of an arrangement for a sorting machine. The sorting machine may include a feed mechanism, an electromagnetic source/detector array, and a control enclosure. The control enclosure may include an analog to digital signal conversion and signal analysis system, and a diverter array system connected to the control enclosure.

A sorter 100 may include a Teflon-lined, steep-sided feed bin suitable for accepting clay or rocky material feed 10, delivering material to a sorting conveyor 20 driven by variable speed motor 30. Material present on the sorting conveyor 20 may be detected by a scanning laser 40 which activates an electromagnetic energy source array 50. Consequent electromagnetic radiation absorption, reflectance or backscatter from the material present in the source energy field may be detected by a detector array 60. Analogue signals from the detector array may then be converted by analogue to digital signal converter 70 to digital form and be passed to a digital signal processing stage 80 where Fourier Analysis is performed to generate a discrete power spectrum analyzed by frequency or wavelength.

Discrete power spectrum data thus generated may then be compared using pattern recognition algorithms to determine the mineral content. Results of the pattern recognition algorithm may then be compared to pre-determined results in an embedded industrial computer 90. A diverter comprising relay/solenoid 110, actuator 120 and gate 130 may be controlled by the embedded industrial computer 90 via the programmable logic controller 100. Material with a recognized chemical composition above a certain pre-set value may be diverted to a product chute 140. Material with a recognized chemical composition below a certain pre-set value may be diverted to a waste chute 150.

FIG. 2 illustrates an example of a control system with embedded pattern recognition and discrimination algorithms. The control system may include an analogue to digital conversion stage, a digital signal processing stage, a pattern recognition stage, comparator stage and a diverter array control stage.

Signals of arbitrary waveform, wavelength and frequency from a detector array 200 may be converted by analog to digital signal converter 210. Digital signals from the converter 210 may be passed to a Fourier Analysis stage where spectral data of amplitude/frequency or amplitude/wavelength format may be generated by Fast Fourier Transform implemented on a field programmable gate array (FPGA) 220 or other suitable device (e.g. a digital signal processor (DSP), application specific IC (ASIC), microcontroller, etc.). Arbitrary power spectra generated 230 in the Fourier Analysis stage 220 may be compared to previously determined and known spectra 260. Spectra of desired material may be recognized by pattern recognition algorithm 240 running on an embedded computer 250. Recognition of desired material may result in “accept” instructions being passed from the embedded computer 250 to the diverter array 280 via a programmable logic controller 270 or other suitable device (e.g. FPGA, DSP, ASIC, microcontroller, etc.). Recognition of undesired material may result in “reject” instructions being passed to a diverter array 280. The equivalency between like components in FIGS. 2 and 1 are evident-detector array 200 of FIG. 2 is equivalent to detector array 60 in FIG. 1; signal converter 210 to signal converter 70; embedded computer 250 to computer 90; diverter array 280 to diverter gate 130; PLC 270 to PLC 100 and so on.

Referring now to the pattern recognition algorithm in more detail, the concepts of recognition and identification as used in biometric security are introduced. Automated digital signal analysis is conventionally applied for pattern recognition using an exact matched, or identified, signal. In spectrum matching, both wavelength and amplitude, or frequency and amplitude of an arbitrary power spectrum are to be matched. Traditional pattern matching requires comparison of every inbound spectrum to the sample spectrum to achieve an exact match and is computationally very intensive and time consuming and therefore not practical in high-speed mineral recognition applications. Recognition is hereby differentiated from identification, or matching, for the purpose of the present system. As used in biometric security, for instance, recognition is the verification of a claim of identity, while identification is the determination of identity. These scenarios loosely correspond to the use of sensor telemetry for classification (e.g., sorting applications in the field) and characterization (e.g., analytical operations in the laboratory). To build further intuition, the biometric identification/recognition scenario will be further elucidated:

Identification

In the laboratory, a sample might be subjected to, for example, an X-ray Fluorescence sensor for analytic purposes. In the mining practice of interest, a spectral pattern is created in the lab using analytical procedures (i.e., samples from the deposit of interest are characterized or identified using analytical procedures in the lab). This is to say that the objective of the sampling is to yield the most accurate and precise result: a sensor-based assay. In this way the identity of a mineral sample as determined by sensor-based techniques is a priori determined. This template is programmed into field units so that results from new samples can be compared to it in quasi-real time.

The biometric analogy might go as follows: You are returning to your home country at one of its major international airports and have the option of using a kiosk equipped with an iris scanner. You simply approach the kiosk and present only your eye for examination by the scanner. The kiosk reads your iris and prints out a receipt with your name on it for you to present to a customs agent. The kiosk has clearly searched for a closest match to the sample you just provided, from a database of templates. You have been identified by the kiosk. Leaving aside the question of whether or not this is good security practice, it is clear that the kiosk is programmed to minimize the possibility of identity fraud (i.e., the incidence of false acceptance).

Recognition

In the field, samples are to be analyzed quickly—in quasi-real time—in order to produce economically viable results. There is neither time nor, as it turns out, need for exactitude in matching. A sample is to simply match the a priori pattern within a pre-determined tolerance; it is then recognized as a positive instance, or else it is classified as a negative instance.

It is therefore necessary only to recognize the emerging spectral pattern, based on the a priori identification described above, in time to make a classification decision.

The biometric analogy might go as follows: You are returning to your home country at one of its major international airports and have the option of using a kiosk equipped with an iris scanner. You approach the kiosk and present your passport, thereby making an identity claim. You then present your eye for examination by the scanner. The kiosk reads your iris and compares the sample to a stored template (derived, perhaps, from information encrypted in your passport). Identity has been rapidly confirmed by recognition of the subject based on a priori knowledge of the subject content. This is analogous to the pattern recognition algorithm deployed in various embodiments of the present invention.

The advanced pattern recognition methodology deployed involves pattern learning (or classification) of absorbed, reflected or backscattered energy from the irradiation of previously characterized mineral samples and pattern recognition comprising fuzzy analysis and resource-bounded matching of absorption, reflectance or backscattered spectra from newly irradiated mineral samples through a trained conditional random field (CRF) algorithm. The algorithms that match of absorption, reflectance or backscattered spectra may be resource-bounded, meaning that energy physics determines when measurement of a sample is complete.

Referring now to the CRF algorithm, CRF involves the “training” of the random field on known spectra, as well as the use of the random field under resource bounded conditions to rapidly recognize new spectra similar to the “trained” spectrum. In contrast to an ordinary matching algorithm which predicts a result for a single sample without regard to “neighboring” samples, the CRF algorithm deployed predicts a likely sequence of results for sequences of input samples analysed. Let X be an array observed spectral measurements with Y a corresponding array of random output spectra. Let S=[V,E]  (1) be a set of spectra such that Y=(Yv)_(v∈V)  (2) so that Y is indexed by the vertices of S. Then (X,Y) is a conditional random field when the random variables Y_(v), conditioned on X, obey the Markov property p(Yv|X,Yw,w≠v)=p(Yv|X,Yw,w˜v)  (3) where w˜v means that w and v are neighbours or near neighbours in S. The conditional distribution p(Y|X)  (4) is then modeled. Learning parameters θ are then obtained by maximum likelihood learning for p(Yi|Xi;θ)  (5) where all nodes have exponential family distributions and optimization is convex and can be solved by, e.g., gradient-descent algorithms. The learning, or characterization, phase involves identifying common characteristic spectra generated from a series of samples by repeated exposure of the spectral analyzer to the samples. These characteristic features may then be used for efficient and rapid spectrum recognition for new samples with similar spectra.

FIG. 2 references therefore a pattern recognition algorithm of the conditional random field type, using back-propagation when in the training mode to define matching coefficients e for the conditional random field, which additionally incorporates pseudo-random sampling, and boundary detection comprising confirmation of the spectral upper and lower bounds. The system is trained to recognize the presence of a range of typical mineral constituents in a matrix such as iron, aluminium, silica and magnesium present in a sample which is moving with reference to the sensor, calculate the specific and total concentration of each element in the sample and compare it to the pre-defined spectrum of known material obtained during the “training” phase of the algorithm development.

Other pattern recognition algorithms such as inter alia brute-force, nearest-neighbour, peak matching etc. may be used. As such, embodiments of the present invention are not limited to the particular algorithm described. For example, the peak frequencies from a few samples with certain amplitudes may be identified, and then each sample may be analyzed for peaks near those frequencies and above a certain amplitude.

FIG. 3 illustrates an example of an arrangement of a sorting system in an open pit mining application. Embodiments depicted in FIG. 3 may be used, for example to classify a pyrometallurgical process feed, a hydrometallurgical process feed and a waste product simultaneously from the same deposit. Typical bulk open pit mining equipment delivers unblended mineral feed to an ore sorting facility comprising arrays of electromagnetic sorting machines described. Saprolitic material produced by the sorting facility is delivered to pyrometallurgical plant 480. Limonitic material simultaneously recovered by the sorting facility is delivered to hydrometallurgical plant 550. Waste material simultaneously recovered by the sorting facility is delivered to waste piles 470, 540 for repatriation to the open pit.

Unblended laterite material 310 from the open pit may be delivered by truck 320 to coarse separator 330. Fine fractions from separator 330 underflow may be passed to fine sorter feed bin 340 where material may be held prior to delivery to sorting conveyor 350. Material travelling on the sorting conveyor 350 may be scanned by an array of electromagnetic sensors 360. Results from the electromagnetic sensors 360 may be passed to controller 370 which compares the sensor results to pre-set values and may instruct the diverter 380 to divert the material according to its chemical content. High iron limonitic material may be diverted to limonite sorter 490. High silica saprolitic material may be diverted to saprolite sorter feed bin 560.

High iron limonitic material from the sorting conveyor 350 may be passed to the limonite sorter feed bin 490 where material is held prior to delivery to sorting conveyor 500. Material traveling on the sorting conveyor 500 may be scanned by an array of electromagnetic sensors 510. Results from the electromagnetic sensors 510 may be passed to controller 520 which compares the sensor results to pre-set values and instructs diverter 530 to divert the material according to its chemical content. Material not suitable for treatment is diverted to the waste pile 540. Limonitic material suitable for treatment is passed via the limonite product conveyor to the hydrometallurgical facility 550.

Similarly high silica saprolitic material from the sorting conveyor 350 may be passed to saprolite sorter feed bin 560 where material may be held prior to delivery to sorting conveyor 570. Material travelling on the sorting conveyor may be scanned by an array of electromagnetic sensors 580. Results from the electromagnetic sensors 580 may be passed to the controller 590 which compares the sensor results to pre-set values and instructs the diverter 600 to divert the material according to its chemical content. Material not suitable for treatment is diverted to the waste pile 540. Saprolitic material suitable for treatment is passed via the saprolite product conveyor 460 to pyrometallurgical facility 480.

Coarse fractions from the separator 330 overflow may be passed to coarse sorter feed bin 410 where material may be held prior to delivery to the sorting conveyor. Material traveling on sorting conveyor 420 may scanned by an array of electromagnetic sensors 430. Results from the array of electromagnetic sensors 430 may be passed to controller 440 which compares the sensor results to pre-set values and instructs the diverter array 450 to divert the material according to its chemical content. High nickel saprolitic material may be diverted to saprolite product conveyor 460. Low nickel, high iron and high silica material may be diverted to the waste pile 470. Note that some elements may be combined together, such as a single controller that performs comparisons and instructs diverters.

FIG. 4 is a flowchart having an example set of instructions for determining mineral content. The operations can be performed by various components such as processors, controllers, and/or other components. In receiving operation 410, response data from a mineral sample is received. The response data may be detected by a scanner that detects the response of the mineral sample to electromagnetic radiation (i.e., reflected or absorbed energy). An analog to digital converter may digitize the response data.

In determining operation 420, the spectral characteristics of the mineral sample may be determined. A spectral analysis may be performed on the response data to determine characteristics of the mineral sample. Characteristics may include frequency, wavelength, and/or amplitude. In some embodiments, characteristics include other user-defined characteristics.

In identifying operation 430, a composition of the mineral sample is identified by comparing the characteristics of the mineral sample to characteristics of known mineral samples. Pattern matching algorithms may be used in identifying the composition.

In assigning operation 440, a composition value is assigned to the mineral sample.

In decision operation 450, it is determined whether the composition value is within a predetermined tolerance of composition values. In reject operation 460, the assigned value of the composition is not within the predetermined tolerance (i.e., the characteristics do not fit with in a pattern), and, thus, the mineral sample is diverted to a waste pile. In accept operation 470, the assigned value of the composition is within the predetermined tolerance (i.e., the characteristics fit within a pattern), and thus, the mineral sample is diverted to a hydrometallurgical or pyrometallurgical process.

Computer System Overview

Embodiments of the present invention include various steps and operations, which have been described above. A variety of these steps and operations may be performed by hardware components or may be embodied in machine-executable instructions, which may be used to cause a general-purpose or special-purpose processor programmed with the instructions to perform the steps. Alternatively, the steps may be performed by a combination of hardware, software, and/or firmware. As such, FIG. 5 is an example of a computer system 500 with which embodiments of the present invention may be utilized. According to the present example, the computer system includes a bus 510, at least one processor 520, at least one communication port 530, a main memory 540, a removable storage media 550, a read only memory 560, and a mass storage 570.

Processor(s) 520 can be any known processor, such as, but not limited to, an Intel® Itanium® or Itanium 2® processor(s); AMD® Opteron® or Athlon MP® processor(s); or Motorola® lines of processors. Communication port(s) 530 can be any of an RS-232 port for use with a modem-based dialup connection, a 10/100 Ethernet port, or a Gigabit port using copper or fiber. Communications may also take place over wireless interfaces. Communication port(s) 530 may be chosen depending on a network such as a Local Area Network (LAN), Wide Area Network (WAN), or any network to which the computer system 500 connects.

Main memory 540 can be Random Access Memory (RAM) or any other dynamic storage device(s) commonly known in the art. Read only memory 560 can be any static storage device(s) such as Programmable Read Only Memory (PROM) chips for storing static information such as instructions for processor 520.

Mass storage 570 can be used to store information and instructions. For example, hard disks such as the Adaptec® family of SCSI drives, an optical disc, an array of disks such as RAID, such as the Adaptec family of RAID drives, or any other mass storage devices may be used.

Bus 510 communicatively couples processor(s) 520 with the other memory, storage and communication blocks. Bus 510 can be a PCI/PCI-X or SCSI based system bus depending on the storage devices used.

Removable storage media 550 can be any kind of external hard-drives, floppy drives, IOMEGA® Zip Drives, Compact Disc-Read Only Memory (CD-ROM), Compact Disc-Re-VWitable (CD-RW), and/or Digital Video Disk-Read Only Memory (DVD-ROM).

Although not required, aspects of the invention may be practiced in the general context of computer-executable instructions, such as routines executed by a general-purpose data processing device, e.g., a server computer, wireless device or personal computer. Those skilled in the relevant art will appreciate that aspects of the invention can be practiced with other communications, data processing, or computer system configurations, including: Internet appliances, hand-held devices (including personal digital assistants (PDAs)), wearable computers, all manner of cellular or mobile phones (including Voice over IP (VoIP) phones), dumb terminals, multi-processor systems, microprocessor-based or programmable consumer electronics, set-top boxes, network PCs, mini-computers, mainframe computers, and the like.

Aspects of the invention can be embodied in a special purpose computer or data processor that is specifically programmed, configured, or constructed to perform one or more of the computer-executable instructions explained in detail herein. While aspects of the invention, such as certain functions, are described as being performed exclusively on a single device, the invention can also be practiced in distributed environments where functions or modules are shared among disparate processing devices, which are linked through a communications network, such as a Local Area Network (LAN), Wide Area Network (WAN), or the Internet. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.

Aspects of the invention may be stored or distributed on tangible computer-readable media, including magnetically or optically readable computer discs, hard-wired or preprogrammed chips (e.g., EEPROM semiconductor chips), nanotechnology memory, biological memory, or other data storage media. Alternatively, computer implemented instructions, data structures, screen displays, and other data under aspects of the invention may be distributed over the Internet or over other networks (including wireless networks), on a propagated signal on a propagation medium (e.g., an electromagnetic wave(s), a sound wave, etc.) over a period of time, or they may be provided on any analog or digital network (packet switched, circuit switched, or other scheme).

CONCLUSION

As one of ordinary skill in the art will appreciate based on the detailed description provided herein, and various novel concepts are realized, some of which are listed below:

-   -   1. A source-detector type electromagnetic sorting system         comprising:         -   a. a device for the introduction of mineral feed to the             sensor;         -   b. a device for the generation of a range of excitation             beams;         -   c. a scanner for the detection of resulting reflected,             absorbed, or backscattered energy;         -   d. an analog to digital converter to digitize both the             signal in (c);         -   e. a software program for signal analysis, data recording,             and process control;         -   f. a control system for processing signal outputs; and         -   g. a diverter connected to the control system for the             diversion of minerals.     -   2. The source-detector type electromagnetic sorting system of         claim 1, wherein the software program comprises:         -   a. a subroutine to convert incoming analog signals to             digital format         -   b. a subroutine to express spectral content of the converted             analog signal         -   c. a subroutine to perform spectral analysis on both             digitized signals in 1(c), determining frequency or             wavelength content and amplitude;         -   d. a subroutine to calibrate the system;         -   e. a subroutine to record the response data in (b) and (c)             along with additional user defined fields;         -   f. a subroutine to compare spectral response data to             previously recorded spectral data from samples of known             composition by means of conditional random field analysis;         -   g. a subroutine to generate a sort signal based on the             comparison in (f); and         -   h. a graphical user interface to control operation and data             recording.     -   3. A method of determining the spectral response of a mineral         sample under irradiation by electromagnetic means using said         system comprising:         -   a. providing said source detector sensing and sorting             system;         -   b. exposing said sensor to a mineral sample;         -   c. converting the spectral response of said mineral sample             to digital format by means of the software program in 1(e);         -   d. measuring the spectral response of said mineral sample to             said sensor by means of the software program in 1(e); and         -   e. converting the measured response (c) into a power             spectrum by means of the software program described in 1(e).         -   f. assigning an appropriate threshold of acceptance for             spectral responses above a certain pre-determined value and             ‘training’ the algorithm to recognize those responses     -   4. A method of determining the mineral composition of an unknown         sample using said sensor comprising:         -   a. providing said system;         -   b. measuring the spectral response due to the unknown             sample;         -   c. using the software program described in 1(e) to compare             the measured data in (b) to previously recorded response             data from samples of known grade as describe in 3; and         -   d. using said software program to assign a compositional             value to the unknown sample based on the comparison in (c).     -   5. A method of discriminating mineral samples based on spectral         response using said sensor comprising:         -   a. providing said system;         -   b. determining characteristic spectral response of the             mineral sample as described in 3 and 4;         -   c. using the software program in 1(e) to compare the values             determined in (b) to predefined spectra of previously             characterized mineral samples by means of the conditional             random field algorithm described; and         -   d. using the control system described in 1(f) to control the             diverter system based upon results of the comparison             described in (c).     -   6. A method of automatically rejecting or accepting mineral         samples based on spectral response using the system of claim 1         comprising the steps of:         -   a. providing said system;         -   b. discriminating between sample materials;         -   c. using the software program in 1(e) to generate a sort             decision based on the discrimination in (b); and         -   d. effecting the sort based on the decision in (c) by means             of the sorting mechanism described in 1 and 2.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof means any connection or coupling, either direct or indirect, between two or more elements; the coupling or connection between the elements can be physical, logical, or a combination thereof. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.

The above Detailed Description of examples of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above. While specific examples for the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. For example, while processes or blocks are presented in a given order, alternative implementations may perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified to provide alternative or subcombinations. Each of these processes or blocks may be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed or implemented in parallel, or may be performed at different times. Further any specific numbers noted herein are only examples: alternative implementations may employ differing values or ranges.

The teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various examples described above can be combined to provide further implementations of the invention. Some alternative implementations of the invention may include not only additional elements to those implementations noted above, but also may include fewer elements. Any patents and applications and other references noted above, including any that may be listed in accompanying filing papers, are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions, and concepts of the various references described above to provide yet further implementations of the invention.

These and other changes can be made to the invention in light of the above Detailed Description. While the above description describes certain examples of the invention, and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Details of the system may vary considerably in its specific implementation, while still being encompassed by the invention disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the invention to the specific examples disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the invention encompasses not only the disclosed examples, but also all equivalent ways of practicing or implementing the invention under the claims.

To reduce the number of claims, certain embodiments of the invention are presented below in certain claim forms, but the applicant contemplates the various aspects of the invention in any number of claim forms. For example, while only one aspect of the invention is recited as a means-plus-function claim under 35 U.S.C sec. 112, sixth paragraph, other aspects may likewise be embodied as a means-plus-function claim, or in other forms, such as being embodied in a computer-readable medium. (Any claims intended to be treated under 35 U.S.C. § 112, ¶6 will begin with the words “means for”, but use of the term “for” in any other context is not intended to invoke treatment under 35 U.S.C. § 112, ¶6.) Accordingly, the applicant reserves the right to pursue additional claims after filing this application to pursue such additional claim forms, in either this application or in a continuing application.

As one of ordinary skill in the art will appreciate based on the detailed description provided herein, and various novel concepts are realized. The Abstract of the Disclosure is provided to comply with 37 C.F.R. section 1.72(b), requiring an abstract that will allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate preferred embodiment: 

We claim:
 1. A sorting system for increasing the recovered value of unblended mineral ore, comprising: a fine fraction sorting system comprising a fine fraction sensor configured to irradiate fine fractions of the unblended mineral ore on a fine fraction conveyor and generate a fine fraction signal indicative of the spectral characteristics of the fine fractions; a fine fraction controller communicatively coupled to the fine fraction sensor and configured to compare the fine fraction signal to spectral characteristics of a known composition to classify the fine fractions into one of a first material or a second material; and a fine fraction diverter movable by the fine fraction controller between a first position and a second position, wherein, when moved to the first position, the fine fraction diverter is configured to direct the fine fractions classified as the first material, and when moved to the second position, the fine fraction diverter is configured to direct the fine fractions classified as the second material; and a first material sorting system for receiving the fine fractions classified as the first material from the fine fraction diverter, the first material sorting system comprising a first material sensor configured to irradiate the fine fractions on a first material conveyor and generate a first material signal indicative of the spectral characteristics of the first material; a first material controller communicatively coupled to the first material sensor and configured to compare the first material signal to spectral characteristics of a known composition to classify the fine fractions into one of a first treatable material or a waste material; and a first material diverter movable by the first material controller between an accept position and a waste position, wherein, when moved to the accept position, the first material diverter is configured to direct the fine fractions classified as the first treatable material to a first material processing facility, and when moved to the waste position, the first material diverter is configured to direct the fine fractions classified as the waste material to a waste pile.
 2. The sorting system of claim 1, further comprising a second material sorting system for receiving the fine fractions classified as the second material from the fine fraction diverter, the second material sorting system comprising: a second material sensor configured to irradiate the fine fractions on a second material conveyor and generate a second material signal indicative of the spectral characteristics of the second material; a second material controller communicatively coupled to the second material sensor and configured to compare the second material signal to spectral characteristics of a known composition to classify the fine fractions into one of a second treatable material or the waste material; and a second material diverter movable by the second material controller between a first position and a second position, wherein, when moved to the first position, the second material diverter is configured to direct the fine fractions classified as the second treatable material to a second material processing facility, and when moved to the second position, the second material diverter is configured to direct the fine fractions classified as the waste material to the waste pile.
 3. The sorting system of claim 1 wherein the fine fraction sensor and the first material sensor are electromagnetic sensors.
 4. The sorting system of claim 1 wherein the fine fraction sensor and the first material sensor are x-ray fluorescence sensors.
 5. The sorting system of claim 1 wherein the first material is a high iron limonitic material, and wherein the first material processing facility is a hydrometallurgical facility.
 6. The sorting system of claim 2 wherein the second material is a high silica saprolitic material, and wherein the second material processing facility is a pyrometallurgical facility.
 7. The sorting system of claim 1, further comprising a coarse separator for separating fine fractions from coarse fractions in the unblended mineral ore.
 8. The sorting system of claim 2, further comprising a coarse fraction sorting system, comprising: a coarse fraction sensor configured to irradiate coarse fractions on a coarse fraction conveyor and generate a coarse fraction signal indicative of the spectral characteristics of the coarse fractions; a coarse fraction controller communicatively coupled to the coarse fraction sensor and configured to compare the coarse fraction signal to spectral characteristics of a known composition to classify the coarse fractions into one of a third material or the waste material; and a coarse fraction diverter movable by the coarse fraction controller between a first position and a second position, wherein, when moved to the first position, the coarse fraction diverter is configured to direct the coarse fractions classified as the third material to the second material processing facility, and when moved to the second position, the coarse fraction diverter is configured to direct the coarse fractions classified as the waste material to the waste pile.
 9. The sorting system of claim 8 wherein the third material is a high nickel saprolitic material, and wherein the second material processing facility is a pyrometallurgical facility.
 10. The sorting system of claim 8 wherein the spectral characteristics of the coarse fractions include at least one of frequency content, wavelength content, or amplitude.
 11. The sorting system of claim 8 wherein the coarse fraction sensor is an x-ray fluorescence sensor.
 12. The sorting system of claim 1 wherein the spectral characteristics of the fine fractions include at least one of frequency content, wavelength content, or amplitude.
 13. The sorting system of claim 1 wherein the spectral characteristics of the known composition are determined using at least one of conditional random field algorithms, Bayesian network, one or more Markov models, neural networks, or fuzzy logic techniques.
 14. The sorting system of claim 1 wherein generation of the fine fraction signal includes measuring reflected, absorbed, or backscattered energy.
 15. A sorting system for increasing the recovered value of unblended mineral ore, comprising: a first material sorting system for receiving fine fractions classified as a first material, the first material sorting system comprising a first material electromagnetic sensor configured to irradiate the fine fractions on a first material conveyor and generate a first material signal indicative of the spectral characteristics of the first material; a first material controller communicatively coupled to the first material electromagnetic sensor and configured to compare the first material signal to spectral characteristics of a known composition to classify the fine fractions into one of a first treatable material or a waste material; and a first material diverter movable by the first material controller between an accept position and a waste position, wherein, when moved to the accept position, the first material diverter is configured to direct the fine fractions classified as the first treatable material to a first material processing facility, and when moved to the waste position, the first material diverter is configured to direct the fine fractions classified as the waste material to a waste pile; a second material sorting system for receiving fine fractions classified as a second material, the second material sorting system comprising— a second material electromagnetic sensor configured to irradiate the fine fractions on a second material conveyor and generate a second material signal indicative of the spectral characteristics of the second material; a second material controller communicatively coupled to the second material electromagnetic sensor and configured to compare the second material signal to spectral characteristics of a known composition to classify the fine fractions into one of a second treatable material or the waste material; and a second material diverter movable by the second material controller between a first position and a second position, wherein, when moved to the first position, the second material diverter is configured to direct the fine fractions classified as the second treatable material to a second material processing facility, and when moved to the second position, the second material diverter is configured to direct the fine fractions classified as the waste material to the waste pile.
 16. The sorting system of claim 15, further comprising a third material sorting system for receiving coarse fractions classified as a third material, comprising: a coarse fraction electromagnetic sensor configured to irradiate coarse fractions on a coarse fraction conveyor and generate a coarse fraction signal indicative of the spectral characteristics of the coarse fractions; a coarse fraction controller communicatively coupled to the coarse fraction electromagnetic sensor and configured to compare the coarse fraction signal to spectral characteristics of a known composition to classify the coarse fractions into one of a third treatable material or the waste material; and a coarse fraction diverter movable by the coarse fraction controller between a first position and a second position, wherein, when moved to the first position, the coarse fraction diverter is configured to direct the coarse fractions classified as the third treatable material to the second material processing facility, and when moved to the second position, the coarse fraction diverter is configured to direct the coarse fractions classified as the waste material to the waste pile.
 17. The sorting system of claim 15 wherein the first material is a high iron limonitic material, and wherein the first material processing facility is a hydrometallurgical facility.
 18. The sorting system of claim 15 wherein the second material is a high silica saprolitic material, and wherein the second material processing facility is a pyrometallurgical facility.
 19. The sorting system of claim 16 wherein the third material is a high nickel saprolitic material, and wherein the second material processing facility is a pyrometallurgical facility.
 20. The sorting system of claim 15 wherein the fine fraction sensor and the first material sensor are x-ray fluorescence sensors. 